Organic Rankine Cycle System with Neural Network Control
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Solution Overview
Problem
Existing Rankine-based heat recovery systems face challenges in adapting to environmental changes and efficiently recovering thermal energy, particularly due to ambient air temperature impacts on air-cooled condensers and the risk of propellant exposure to flame.
Innovation Solution
A system comprising a reciprocating engine, a circulating pump, heat exchangers, an expander, and a condenser, operating an organic Rankine cycle with a monitoring module and control module to optimize thermal energy recovery and conversion to mechanical energy, while minimizing exposure risks and adapting to environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If an organic Rankine cycle system is used to recover thermal energy, then thermal energy recovery efficiency is improved, but the risk of propellant exposure to flame increases
Solution Approach 1:
The patent introduces a heat exchanger as an intermediary component that transfers thermal energy from the engine exhaust to the organic propellant without direct contact. This mediator allows efficient thermal energy recovery while preventing the propellant from being exposed to flame or high-temperature combustion gases, thus resolving the contradiction between recovery efficiency and safety risk
Solution Approach 2:
The system separates the thermal energy recovery process into distinct stages: the engine exhaust flows through one path while the organic propellant flows through a separate path in the heat exchanger. This segmentation allows thermal energy transfer while maintaining physical separation between the propellant and flame, enabling efficient recovery without exposure risk
2Device complexity
If air-cooled condensers are used in the Rankine cycle system, then system simplicity is improved, but adaptability to environmental changes deteriorates
Solution Approach 1:
The patent implements a control system that dynamically adjusts the operation of air-cooled condensers based on ambient temperature conditions. The system monitors environmental changes and modifies condenser performance accordingly, enabling adaptation to varying environmental conditions while maintaining the simplicity of air-cooled design without complex water cooling infrastructure
Solution Approach 2:
The system changes operating parameters such as fan speed, air flow rate, and condenser surface area utilization in response to ambient temperature variations. By dynamically adjusting these parameters, the simple air-cooled condenser system can adapt its performance to match environmental conditions, resolving the contradiction between simplicity and adaptability
3Productivity
If the Rankine cycle operates at maximum power output, then productivity is improved, but system reliability deteriorates due to increased exposure risks
Solution Approach 1:
The patent incorporates a control system with sensors that continuously monitor system operating conditions, propellant state, and thermal energy recovery rates. This feedback mechanism allows the system to operate at maximum power output while detecting and responding to conditions that could lead to propellant exposure, automatically adjusting operations to maintain both productivity and reliability
Solution Approach 2:
The system implements protective measures and safety margins in advance of potential failure conditions. The heat exchanger design includes safety factors and the control system is programmed with predetermined safety thresholds that prevent operation under conditions that could lead to propellant exposure, allowing maximum power output within safe operating boundaries
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively recovers thermal energy from a reciprocating engine, converts it into secondary mechanical power, and adapts to environmental changes, enhancing system efficiency and safety by using predictive models to regulate operation.
Implementation Method 1
thermal energy is transferred to a liquid organic propellant in the propellant heat exchanger in the ORC to evaporate the propellant
Implementation Method 2
evaporate the propellant, which gaseous propellant then drives the expander
Implementation Method 3
gaseous propellant then drives the expander in production of mechanical energy
Implementation Method 4
operating an organic Rankine cycle with a monitoring module and control module to optimize thermal energy recovery and conversion to mechanical energy
Implementation Method 5
propellant from the expander condensed back into liquid form by the condenser
Data Source
AI summary
Technologies and techniques for converting thermal energy into mechanical and/or electric energy using an integrated thermal energy recovery system. This system employs an Organic Rankine Cycle (ORC) with a propellant heat exchanger, an expander, and a condenser, coupled with heat exchangers for transferring waste heat from an engine to ORC propellant. Sensors generate data reflecting environmental and operational conditions. A control circuit, incorporating a predictive module trained on a neural network, identifies non-linear relationships and sequences for optimizing ORC performance. The control circuit analyzes sensor data to determine if target operational values for waste heat recovery and power generation can be achieved within a specific timeframe. If not, the circuit dynamically adjusts the system via control signals to optimize net power by managing heat flow between thermal fluids, engine jacket water, engine exhaust, and/or ORC propellant to maintain target values.